Additive manufacturing method and apparatus

ABSTRACT

An apparatus for forming a three-dimensional article is provided, comprising means for providing a predetermined amount of powder, a powder distributor, means for directing an energy beam over a first powder layer causing it fuse in selected locations according to a model, a camera for capturing at least one image of a shape of at least one portion of the predetermined amount of powder that has yet to be initially distributed, the at least one image being captured prior to distribution of an entirety of all portions of the predetermined amount of powder over the surface, and means for comparing at least one value of at least one parameter in the image detected with a corresponding reference parameter value, wherein the at least one parameter is associated with the shape of the powder that has yet to be initially distributed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional patent application of U.S.Nonprovisional patent application Ser. No. 14/443,015, filed May 14,2015, which is a National Stage Application, filed under 35 U.S.C. §371, of International Application No. PCT/EP2013/074092, filed Nov. 18,2013, which claims priority to U.S. Provisional Application No.61/738,203, filed Dec. 17, 2012, the contents of all of which as arehereby incorporated by reference in their entirety.

BACKGROUND Related Field

The present invention relates to an apparatus for forming athree-dimensional article according to the claims provided herein.

Description of Related Art

Freeform fabrication or additive manufacturing is a method for formingthree-dimensional articles through successive fusion of chosen parts ofpowder layers applied to a worktable. A method and apparatus accordingto this technique is disclosed in US 2009/0152771.

Such an apparatus may comprise a start plate on which saidthree-dimensional article is to be formed, a powder dispenser, arrangedto lay down a thin layer of powder on the start plate for the formationof a powder bed, a ray gun for delivering energy to the powder wherebyfusion of the powder takes place, elements for control of the ray givenoff by the ray gun over said powder bed for the formation of a crosssection of said three-dimensional article through fusion of parts ofsaid powder bed, and a controlling computer, in which information isstored concerning consecutive cross sections of the three-dimensionalarticle. A three-dimensional article is formed through consecutivefusions of consecutively formed cross sections of powder layers,successively laid down by the powder dispenser.

In US 2009/0152771 it is provided a camera for capturing anInfrared-radiation image, more particularly this camera is used fordetecting irregularities in a newly applied powder layer. Theirregularities may, according to US 2009/0152771, be caused by irregularapplying of the powder on the working table or contamination in thepowder dispenser or impurities in the powder as such. There is a need inthe art for a method and apparatus in which the cause for irregularpowder distribution may be detected for future repair in the additivemanufacturing system.

BRIEF SUMMARY

An object of the invention is to provide a method and apparatus whichsolve the above mentioned need in the art. This object is achieved bythe features in the method according to the claims provided herein.

In a first aspect of the invention it is provided a method for forming athree-dimensional article through successive fusion of parts of a powderbed, which parts corresponds to successive cross sections of thethree-dimensional article, said method comprising the steps of: (a)providing a predetermined amount of powder for forming a first powderlayer on a surface, (b) distributing said predetermined amount of powderfor forming said first powder layer on said surface, (c) directing anenergy beam over said first powder layer causing said first powder layerto fuse in selected locations according to a model to form a first crosssection of said three-dimensional article, (d) capturing at least oneimage of the powder to be distributed with a camera at least one timeduring said distribution of said powder on said surface for forming saidfirst powder layer, and (e) comparing at least one value of at least oneparameter in said image detected by said camera with a correspondingreference parameter value.

An advantage of this embodiment is that an indication of an error in thebuild may be given already in the powder distribution phase. A messagemay be sent to the operator that the powder distribution may beincorrect and/or said position of the powder distributor and the numberof the layer in which this happened may be stored in a control unit.

In one example embodiment of the present invention said predeterminedamount of powder for forming a second powder layer on top of said firstpowder layer which is fused in selected locations may change if at leastone parameter value in said image is deviating at least one Δ-value froma corresponding reference parameter value.

An advantage of this embodiment is that there may be a feed back to apowder provision mechanism in which the amount of powder is changedduring building the article. Increasing the powder amount if there is anindication of too less powder during the powder distribution process anddecreasing the powder amount if there is an indication that there is toomuch powder which is distributed over the start plate for forming apowder layer.

In another example embodiment according to the present invention asecond predetermined amount of powder is provided for forming said firstpowder layer a second time and distributing said second predeterminedamount of powder for forming said first powder layer said second time ifat least one parameter value in said image is at least one Δ-valuesmaller than a corresponding reference parameter value when forming saidfirst powder layer said first time.

An advantage of this embodiment is that any failure in the powderapplication mechanism may be corrected before starting to fuse thepowder layer and thereby creating defects in the three-dimensionalarticle because of a non-homogenous powder layer.

In another example embodiment of the present invention said parameter insaid image may be one of the group of: shape of powder in front of apowder distributor; distance of powder front to a reference position;width of powder front and/or position of powder front.

An advantage of this embodiment is that a number of different parametersmay be used in order to check the powder distribution process and theresulting powder layer that comes from this distribution process.Deviations from a predetermined reference value of any one of saidparameters may be an indication of an erroneous powder layer. In such acase one may start a second powder application process for such a layer,i.e., the erroneous powder layer may immediately started to be repairedbefore the powder layer is fused in selected locations.

In another aspect of the invention it is provided an apparatus forforming a three-dimensional article through successive fusion of partsof a powder bed, which parts corresponds to successive cross sections ofthe three-dimensional article, said apparatus comprising: (a) means forproviding a predetermined amount of powder for forming a first powderlayer on a surface, (b) a powder distributor for distributing saidpredetermined amount of powder for forming said first powder layer, (c)means for directing an energy beam over said first powder layer causingsaid first powder layer to fuse in selected locations according to amodel to form a first cross section of said three-dimensional article,(d) a camera for capturing at least one image of the powder to bedistributed at least one time during said distribution of said powder onsaid surface for forming said first powder layer, and (e) means forcomparing at least one value of at least one parameter in said imagedetected by said camera with a corresponding reference parameter value.

Further example embodiment of the apparatus is evident from thedescription, figures and dependent claims. The advantage of thedifferent embodiments of the apparatus is similar to the advantage ofthe corresponding method and need therefore not to be repeated in thiscontext.

BRIEF DESCRIPTION OF THE FIGURES

The invention will be further described in the following, in anon-limiting way with reference to the accompanying drawings. Samecharacters of reference are employed to indicate corresponding similarparts throughout the several figures of the drawings:

FIG. 1 depicts a top view camera image of a powder distribution process;

FIG. 2 depicts a side view of a part of an example embodiment of anadditive manufacturing apparatus according to the present invention;

FIG. 3 depicts schematic side view of an example embodiment of anadditive manufacturing apparatus according to the present invention;

FIG. 4a depicts a flow chart of a first example embodiment of the methodaccording to the present invention;

FIG. 4b depicts a flow chart of a second example embodiment of themethod according to the present invention;

FIG. 4c depicts a flow chart of a third example embodiment of the methodaccording to the present invention;

FIG. 5 depicts a side view of an alternative powder distributionprocess;

FIG. 6 depicts a side view of an alternative powder distribution processaccording to prior art; and

FIG. 7 depicts alternative parameter values taken from a single image.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

To facilitate the understanding of this invention, a number of terms arebelow. Terms defined herein have meanings as commonly understood by aperson of ordinary skill in the areas relevant to the present invention.Terms such as “a”, “an” and “the” are not intended to refer to only asingular entity, but include the general class of which a specificexample may be used for illustration. The terminology herein is used todescribe specific embodiments of the invention, but their usage does notdelimit the invention, except as outlined in the claims.

The term “three-dimensional structures” and the like as used hereinrefer generally to intended or actually fabricated three-dimensionalconfigurations (e.g. of structural material or materials) that areintended to be used for a particular purpose. Such structures, etc. may,for example, be designed with the aid of a three-dimensional CAD system.

The term “electron beam” as used herein in various embodiments refers toany charged particle beam. The source of a charged particle beam caninclude an electron gun, a linear accelerator and so on.

FIG. 2 depicts side view of a part of an additive manufacturingapparatus according to the present invention, and FIG. 3 depicts aschematic side view of a freeform fabrication or additive manufacturingapparatus 300 according to of the present invention. Said apparatus 300comprising an electron gun 302; a camera 304, 260; powder hoppers 208,306, 307; a start plate 316; a build tank 312, 240; a powder distributor310, 202; a powder table 230, 340; a build platform 314, 206; a vacuumchamber 320 and a control unit 270, 370.

The vacuum chamber 320 is capable of maintaining a vacuum environment bymeans of a vacuum system, which system may comprise a turbo molecularpump, a scroll pump, an ion pump and one or more valves which are wellknown to a skilled person in the art and therefore need no furtherexplanation in this context. The vacuum system may be controlled by acontrol unit 270, 370.

The electron gun 302 is generating an electron beam which is used formelting or fusing together powder material 318 provided on the startplate 316. At least a portion of the electron gun 302 may be provided inthe vacuum chamber 320. A control unit 270, 370 may be used forcontrolling and managing the electron beam emitted from the electronbeam gun 302. At least one focusing coil (not shown), at least onedeflection coil and an electron beam power supply may be electricallyconnected to said control unit 270, 370. In an example embodiment of theinvention said electron gun generates a focusable electron beam with anaccelerating voltage of about 60 kV and with a beam power in the rangeof 0-3 kW. The pressure in the vacuum chamber may be in the range of10-3-10-6 mBar when building the three-dimensional article by fusing thepowder layer by layer with the energy beam.

Instead of melting the powder material with an electron beam a laserbeam may be used.

The powder hoppers 306, 307 comprise the powder material to be providedon the start plate 316 in the build tank 312. The powder material mayfor instance be pure metals or metal alloys such as titanium, titaniumalloys, aluminum, aluminum alloys, stainless steel, Co—Cr—W alloy, etc.

The powder distributor 310 is arranged to lay down a thin layer of thepowder material on the start plate 316. During a work cycle the buildplatform 314 will be lowered successively in relation to the ray gunafter each added layer of powder material. In order to make thismovement possible, the build platform 314, 206 is in one embodiment ofthe invention arranged movably in vertical direction, i.e., in thedirection indicated by arrow P. This means that the build platform 314,206 starts in an initial position, in which a first powder materiallayer of necessary thickness has been laid down on said start plate 316.A first layer of powder material may be thicker than the other appliedlayers. The reason for starting with a first layer which is thicker thanthe other layers is that one does not want a melt-through of the firstlayer onto the start plate. The build platform is thereafter lowered inconnection with laying down a new powder material layer for theformation of a new cross section of a three-dimensional article. Meansfor lowering the build platform 314, 206 may for instance be through aservo engine equipped with a gear, adjusting screws etc.

In an example embodiment said start plate 316 may be said build platform314, 206. In such case said build platform 314, 206 is removable fromthe build tank 312.

In an example embodiment of a method, a three-dimensional article may beformed through successive fusion of parts of a powder bed, which partscorresponds to successive cross sections of the three-dimensionalarticle, comprising a step of providing a model of said threedimensional article. Said model may be generated via a CAD (ComputerAided Design) tool.

A predetermined amount of powder may be provided at a powder table 230,340 denoted by step 402 in FIG. 4a . Said predetermined amount of powderis in the illustrated example embodiment provided on said powder table230, 340 by means of a powder hopper 306, 307, 208 provided with anopening at the bottom end which is creating a screen of powder 220 onsaid powder table 230.

Instead of providing the powder from said powder hopper on said powdertable an arrangement according to FIG. 5 may be used. In FIG. 5 a powdercontainer 360 with a movable floor us used for providing a predeterminedamount of powder. The movable floor may be moved in a vertical directionindicated by the arrow 368 in FIG. 5. The build tank for building the3-dimensional article is arranged beside said powder container. Ipredetermined amount of powder is provided by increasing the height ofthe floor in said powder container thereby lifting a predeterminedamount of powder from said powder container. A powder distributor 202may thereafter rake said powder which is lifted up from the powdercontainer and distribute said powder on said build platform 314. Theamount of powder to be distributed from said powder container may easilybe changed by changing the distance said floor is lifted up from saidpowder container. A control computer 270 may be controlling the liftingof said floor 362 in said powder container 360, which may be with amotor connected to a shaft 366 which may in turn connected to said floor362. Said control computer may also control the lowering of said buildplatform 314 in said build tank 312.

A first powder layer may be provided on the start plate 316. In anexample embodiment the first powder layer is provided on a surface whichmay be a start plate or a powder bed.

In a first example embodiment powder may be collected by a powderdistributor or a rake 202, 310 by moving the rake 202, 310 with itsfirst surface 290 a predetermined distance in a first direction into thescree of powder 220 allowing a predetermined amount of powder to fallover a top of said rake 202. The rake 202 is then moved in a seconddirection, opposite to said first direction, and thereby removing saidpredetermined amount of powder which has fallen over the top of saidrake 202, 310 from said scree of powder with a second surface 291 ofsaid rake 202, 310.

In an alternative method said powder to be distributed over said startplate 316 may be collected from a powder container 360 with a movablebottom as described in connection with FIG. 5 above.

The powder removed from the scree of powder 220 or scraped off from thepowder container 360 or provided by any other suitable mechanism infront of the rake 202 may be moved over the build tank 312, 240 by meansof said rake 202, 310, thereby distributing the powder over the startplate 316 or said build platform 314, 206 denoted by step 404 in FIG. 4a.

The distance between a lower part of the rake and the upper part of thestart plate or previous powder layer determines the thickness of powderdistributed over the start plate. The powder layer thickness can easilybe adjusted by adjusting the height of the build platform 314, 206.

An energy beam may be directed over said start plate 316 causing saidfirst powder layer to fuse in selected locations to form a first crosssection of said three-dimensional article according to said modelgenerated via said CAD tool denoted with step 406 in FIG. 4 a.

The energy beam may be an electron beam or a laser beam. The beam isdirected over said start plate 316 from instructions given by thecontrol unit 270, 370. In the control unit 270, 370 instructions for howto control the beam gun for each layer of the three-dimensional articlemay be stored.

After a first layer is finished, i.e., the fusion of powder material formaking a first layer of the three-dimensional article, a second powderlayer is provided on said start plate 316. The second powder layer ispreferably distributed according to the same manner as the previouslayer. However, there might be alternative methods in the same additivemanufacturing machine for distributing powder onto the work table 316.For instance, a first layer may be provided by means of a first powderdistributor, a second layer may be provided by another powderdistributor. The design of the powder distributor is automaticallychanged according to instructions from the control unit. A powderdistributor in the form of a single rake system, i.e., where one rake iscatching powder fallen down from both a left powder hopper 306 and aright powder hopper 307, the rake as such can change design.

After having distributed the second powder layer on the work table 316,the energy beam is directed over said work table 316 causing said secondpowder layer to fuse in selected locations to form a second crosssection of said three-dimensional article.

Fused portions in the second layer may be bonded to fused portions ofsaid first layer. The fused portions in the first and second layer maybe melted together by melting not only the powder in the uppermost layerbut also remelting at least a fraction of a thickness of a layerdirectly below said uppermost layer.

An image may be captured of the powder to be distributed with a cameraat least one time during the distribution of powder over the work table316 for forming a powder layer denoted by 408 in FIG. 4a . The image maybe taken by the camera 304 provided inside or outside the vacuum chamber320. The camera 304 may be any type of camera for example an IR-camera(Infrared-camera), NIR-camera (Near Infrared-camera), a VISNIR-camera(Visual Near Infrared-camera), a CCD camera (Charged CoupledDevice-camera), a CMOS-camera (Complementary Metal OxideSemiconductor-camera), a digital camera.

FIG. 1 illustrates a possible example of such an image 100 of the powderto be distributed. The image is taken from above, i.e., a top view ofthe powder layer and the powder distributor 202. In FIG. 1 area 102represents an area on which a new powder already has been provided. Area104 represents the powder distributor 202 and powder which is to bedistributed and is provided in front of the powder distributor 202. Area108 represents the previous layer or a blank start plate 316. Powder tobe distributed is concentrated in an area 106 to the right of the topportion 292 of the powder distributor. The skilled person willunderstand that different shapes of powder distributor may be used thanthe one in the example embodiments.

FIG. 6 depicts from a side view a powder distribution mechanism. Thepowder distributor 202 is distributing the powder 204 in front of thepowder distributor 202 on said build platform 206. During the powderdistribution process over said build platform 206 the distance X, whichis the distance from the back portion of the powder distributor to thefront portion of the powder which is to be distributed, is varied due tothe fact that powder is consumed as it is provided on top of the buildplatform as the powder distributor is moving across the build platform.The value of X may be an indication of insufficient or a surplus ofpowder in front of the powder distributor at any given position duringthe powder distribution process.

At least one image may be taken during the distribution of powder forforming a powder layer on the start plate 316. In an example embodimentimages are taken at the start of powder distribution and at the end ofpowder distribution. In another example embodiment images may also betaken at any position between said start and finish of the powderdistribution.

At least one value of at least one parameter in at least one image whichmay be detected with said camera may be compared with a correspondingreference parameter value denoted with 410 in FIG. 4a . In an exampleembodiment a distance of the powder front to a reference position may bea reference parameter. Reference parameters may be stored in a look uptable. Said reference position may for instance be any part of thepowder distributor such as the front side or backside. The referenceposition may also be a fixed position within the build chamber, such asa predetermined position of the vacuum chamber.

The shape of powder in front of the powder distributor and/or thedistance to back or front of the powder distributor to a powder front120 may be examples of said parameter in said image. Reference images ofshapes of powder in front of the powder distributor may be stored in thecontrol unit for comparison with the actual shape. If the shape isdeviating more than a predetermined amount from any one of the storedimages a warning message may be sent out and/or stored in the controlunit 270. The reference shape may for instance be a suitablemathematical expression, such as a polynomial or a parabola or any othershape that is desired for the powder front to be at any given timeduring the powder distribution process. This mathematical expression maybe compared to the actual image taken of the powder front. In a look uptable it may be stored the desired shape of the powder front at a giventime. This shape from the look up table may be compared with the actualvalue and any difference that is deviating more than a Δ-value from thedesired shape may be a sign of a failure in the powder distributionprocess. The shape of the powder front in the image may be approximatedwith a given mathematical expression such as A+BX+CX2+DX3, where A, B, Cand D are constants. If any one of the constants in the approximatedpolynomial from said image is deviating more than a Δ-value from acorresponding constant in the reference polynomial, this may be a signof a failure in the powder distribution process. Said Δ-value may bedifferent for different constants in a given polynomial. The value of Δmay be set depending on the tolerance of a difference between desiredand actual shape of the powder front, larger Δ-value indicated a largertolerance for differences than a smaller Δ-value.

Any other parameter than the shape may be stored in a look up table suchas the distances mentioned below. As with the shape said distances havea desired value for any given time and may be compared with the actualvalue. If there is a difference larger than a Δ-value between saiddesired value and said actual value such a difference may be anindication of a failure in the powder distribution process.

In FIG. 7 it is depicted examples of different parameter values whichmay be taken from a single camera image. Not only a comparison of theshape of the powder front as was discussed above may be possible tocompare with stored reference images but also the distance of the powderfront to a front side 710, denoted by Y, or to a back side 720 denotedby X. If the distance from the actual image at a given position of thepowder distributor is deviating more than a Δ-value from a stored valuefor the powder distributor at the given position of said powderdistributor a warning signal may be sent to the control computer 270. Adistance from a first end portion 770 of the powder front 120 to a firstend of the powder distributor 740 is another parameter value which maybe of interest which is denoted by Z1 in FIG. 7. A distance from asecond end portion 780 of the powder front 120 to a second end of thepowder distributor 730 is still another parameter value which may be ofinterest which is denoted by Z2 in FIG. 7. Despite the fact that theshape of the powder front may be correct, said powder front may beoffset in one or another direction resulting in different values of Z 1and Z2. If the difference between Z1 and Z2 is deviating more than apredetermined value a signal may be sent to the control computer 270.Another parameter which may be of interest is the length of the powderfront from the first end portion 770 to the second end portion 780. Thisparameter value is denoted by Z3 in FIG. 7. The reference parameters maybe stored in a look up table which in turn may be located in or inconnection to the control computer 270. Reference parameterscorresponding to the above mentioned X, Y, Z1, Z2, Z3 may be found insuch a look up table for a number of positions of the powderdistributor. Such reference parameters may be different for differentmaterials and different thicknesses of the powder layer.

In said control unit 270 there may also be several values stored forsaid distance of powder front to said powder distributor which may becompared with actual distances of the powder front 120 to the powderdistributor. In an example embodiment several measurements of saiddistance of said powder front to said powder distributor 202 may betaken from a single image, i.e., at several positions along the powderdistributor 202. By taking more than one measurement of said distanceone may make assure that the powder is not unevenly distributed in frontof the powder distributor 202. Unevenly distributed powder may possiblybe the cause for unevenly distributed powder, i.e., less or no powder ata specific location. If the measured distance of the powder front tosaid powder distributor 202 for any distance of the powder distributor202 and any position along the powder distributor 202 is deviating morethan a predetermined value from a reference value of a correspondingreference distance of the powder front to the powder distributor 202 awarning message may be sent out and/or said position of said powderdistributor 202 together with said position along said powderdistributor 202 may be stored in said control unit 270.

FIG. 4b depicts another example embodiment of the method according tothe present invention. The steps 402, 404, 406, 408 and 410 are equal tothe steps in FIG. 4a . If the comparison in step 410 reveals that thereis no difference between the reference parameter value and the actualmeasured value from the image the next layer is provided on the startplate 316 with the same settings for the powder distributor. The box N+1indicates that the layer N+1 is to be provided on the start plate 316and therefore starts all over from step 402, where N is an integer beinglarger than 1 and equals to the number of the previous layer of powderbeing distributed on the start plate 316. On the other hand, if there isa difference between the actual measured value and the reference valuethe method may go to step 414 after 410. In an example embodiment saiddifference needs to be greater than a predetermined Δ-value in order tomove from step 410 to step 414. Said predetermined Δ-value may be setdifferent for different powder thickness and/or different materialsand/or different powder provision mechanism.

In step 414 a different amount of powder is provided on the worktable. Adifferent amount of powder could be provided by changing the distancethat said powder distributor 202 is travelling into the scree of powder220 before being stopped.

Alternatively a different amount of powder could be provided by changingthe distance said movable floor 362 is lifted. A less distance willprovide less powder and a longer distance will provide more powder. Instep 416 the changed amount of powder is distributed on the start plate316 for forming layer N+1. In an example embodiment the amount of powderat the end of the powder distribution process may indicate a superfluousamount of powder in front of the powder distributor although the powderdistribution has been finished. In such case the amount of powder may bereduced for the following layer.

As disclosed above the powder distributor 202 may be set to travel aless distance into the scree of powder 220 in order to let a less amountof powder to fall over the top of the powder distributor. On the otherhand, if the measurement indicates that the powder in front of thepowder distributor is decreasing, the settings of the powder distributormay be changed in order to collect more powder from the scree of powder220. As an alternative to provide less powder in front of the powderdistributor, said floor in said powder tank may be set to travel a lessdistance upwards thereby providing a less amount of powder which ispossible to be raked off by the powder distributor and to be distributedon said start plate 206, 314.

FIG. 4c depicts yet an alternative example embodiment of the methodaccording to the present invention. If there is no difference betweenthe actual measured parameter value and a predetermined referenceparameter value, the next powder layer may be started to be distributedwith the same settings as the previous powder layer indicated in FIG. 4cwith a line connecting together step 410 and step 402.

If the measured parameter value is in fact more than a predeterminedvalue from the reference parameter value, then the next question may be,denoted in FIG. 4c with 418, “less than the reference parameter value”?If the answer to said question is “NO”, then step 414 and 416 applieswhich is disclosed in relation to FIG. 4b . However, if the answer is“YES”, then step 420 applies. In step 420 a second predetermined amountof powder may be provided for forming said first powder layer for asecond time and distributing said second predetermined amount of powderfor forming said first powder layer for said second time. If at anyposition the actual measured parameter value is less than the referenceparameter value there may a risk that no powder is distributed at one ormore locations of the start plate 316. In order to make sure that powderis evenly distributed all over the work table 316 another powderdistribution is taking place for forming the same powder layer a secondtime. This is indicated in FIG. 4c by connecting 420 between step 402and step 404. In step 402 it is provided a predetermined amount ofpowder on the powder table to be distributed over the start plate 316for forming layer N.

In step 420 a second predetermined amount of powder may be provided onsaid powder table for forming layer N. Said second predetermined amountof powder may be different to said predetermined amount of powder instep 402. Since a second powder distribution is taking place afterproviding the second predetermined amount of powder for forming layer Na relatively small amount of powder is needed to fill in the possibleholes/gaps in the layer already provided at the first instance. Asmaller amount of powder may be collected from the scree of powder byletting the powder distributor travelling a less distance into the screeof powder than normally, i.e., in the case when said predeterminedamount of powder is provided on said powder table said powderdistributor is travelling a first distance into the scree of powder andwhen said second amount of powder may be provided on said powder tablesaid powder distributor may be travelling a second distance into thescree of powder. Here the second distance may be less than said firstdistance in order to collect less powder in the second collection fordistribution over the start plate 316 a second time for forming layer N.Alternatively a different amount of powder could be provided by changingthe distance said movable floor 362 may be lifted upwards.

A feedback signal may be generated if there is a mismatch between themeasured parameter value and a corresponding reference parameter value.The feedback signal may go from the control unit 270 to a powderprovision apparatus for changing the amount of powder provided on saidpowder table. In an example embodiment no powder table may be present.The amount of powder provided may in such case be achieved by changingthe distance said movable floor 362 is lifted upwards.

In another aspect of the invention it is provided an apparatus forforming a three-dimensional article through successive fusion of partsof a powder bed, which parts corresponds to successive cross sections ofthe three-dimensional article. Said apparatus may comprise means forproviding a predetermined amount of powder at a powder table for forminga first powder layer on a start plate. Said means for providing apredetermined amount of powder at said powder table may be a powderhopper as indicated in FIGS. 2 and 3 with an opening at the bottom forcreating a scree of powder on said powder table. Another means forproviding powder on said powder table may be a rotating barrel which foreach revolution ejects at least once a predetermined amount of powder.Another means for providing powder may be a powder hopper with anopening at the bottom. A mechanical shutter may open and close theopening for providing a predetermined amount of powder below saidopening. As the skilled person realises there exist numerous ways ofproviding powder on said powder table and the examples above is just afew of them. Said apparatus further comprises a powder distributor fordistributing said predetermined amount of powder for forming said firstpowder layer and means for directing an energy beam over said startplate causing said first powder layer to fuse in selected locationsaccording to a model to form a first cross section of saidthree-dimensional article. Said means for directing the energy beam maybe a magnetic coil if the energy beam is in the form of an electronbeam. If the beam is in the form of a laser beam said means fordirecting the beam may be a reflecting mirror which is tiltable.

Said apparatus further comprising a camera for capturing at least oneimage of the powder to be distributed at least one time during saiddistribution of said powder on said start plate for forming said firstpowder layer and means for comparing at least one value of at least oneparameter in said image detected by said camera with a referenceparameter value.

The means for comparing parameter values from the image with referencevalues may be a software program which makes analysis and measurementsat predetermined image locations and comparing these measurements withstored reference values. Said apparatus may further be provided with afeature which provides for an alarm if the measured value and thereference value differs more than a predetermined value from each other.Another feature that said apparatus may be provided with is a storingfunction which stores the location of the powder distributor if themeasured value and the reference value differs more than a predeterminedvalue from each other.

In another example embodiment of said apparatus there is provided meansfor changing said predetermined amount of powder for forming a secondpowder layer on said start plate if at least one parameter value in saidimage is deviating from said reference parameter value. Said means maybe programmable instructions sent from the control unit 270 to thepowder distributor indicating that the distance of travel into the screeof powder is changed. In an alternative design of said provision ofpowder, e.g., in case of a shutter in front of the bottom opening of apowder hopper, the time and/or the area of opening of said shutter maybe changed in order to change the predetermined amount of powder.

In still another example embodiment said apparatus comprises means forproviding a second predetermined amount of powder for forming said firstpowder layer and distributing said second predetermined amount of powderfor forming said first powder layer if at least one parameter value isless than a reference parameter value. The means may be the same asdisclosed above for providing the second predetermined amount of powder,i.e., it may be a question of settings of the powder distributor orshutter which determines the amount of powder provided on said powdertable. A second powder distribution for forming one and the same powderlayer may take place if there may be an indication that there may be oneor more places of nonsufficient powder.

The energy beam, which may be a laser beam or an electron beam, not onlymelts the last applied powder layer but also at least the layer ofmaterial below the powder layer resulting in a melt comprising thepowder material and already melted material from a previous fusionprocess.

The invention is not limited to the above-described embodiments and manymodifications are possible within the scope of the following claims.Such modifications may, for example, involve using a different source ofray gun than the exemplified electron beam such as laser beam. Othermaterials than metallic powder may be used such as powders of polymersand powder of ceramics.

The invention claimed is:
 1. An apparatus for forming athree-dimensional article through successive fusion of parts of a powderbed, which parts corresponds to successive cross sections of thethree-dimensional article, said apparatus comprising: means forproviding a predetermined amount of powder for forming a first powderlayer on a surface, a powder distributor for distributing saidpredetermined amount of powder for forming said first powder layer,means for directing an energy beam over said first powder layer causingsaid first powder layer to fuse in selected locations according to amodel to form a first cross section of said three-dimensional article, acamera; and a control unit including software that, when executed by aprocessor, causes the apparatus to: capture at least one image of ashape of at least one portion of said predetermined amount of powderthat has yet to be initially distributed, said at least one image beingcaptured at least one time during said initial distribution of anotherportion of said predetermined amount of powder to said surface, said atleast one image being captured prior to distribution of an entirety ofall portions of said predetermined amount of powder over said surfaceand prior to removal of any portions of said predetermined amount ofpowder from said surface, and compare at least one value of at least oneparameter in said image detected by said camera with a correspondingreference parameter value, wherein the at least one parameter isassociated with said shape of said at least one portion of saidpredetermined amount of powder that has yet to be initially distributed.2. The apparatus according to claim 1, further comprising means forchanging said predetermined amount of powder for forming a second powderlayer on top of said first powder layer which is fused in selectedlocations if at least one parameter value in said image of said powderwhen forming said first powder layer is deviating at least one Δ-valuefrom a corresponding reference parameter value.
 3. The apparatusaccording to claim 1, further comprising means for providing a secondpredetermined amount of powder for forming said first powder layer asecond time and distributing said second predetermined amount of powderfor forming said first powder layer said second time if at least oneparameter value in said image is at least one Δ-value smaller than acorresponding reference parameter value when forming said first powderlayer said first time.
 4. The apparatus according to claim 3, whereinsaid predetermined amount of powder is different than said secondpredetermined amount of powder.
 5. The apparatus according to claim 1,wherein said image is captured by at least one of an IR-camera, aCCD-camera, a digital camera, a CMOS camera or a NIR-camera.
 6. Theapparatus according to claim 1, wherein said parameter in said image maybe one of the group of: shape of powder in front of a powderdistributor; distance of powder front to a reference position; width ofpowder front and/or position of powder front.
 7. The apparatus accordingto claim 1, wherein said surface on top of which said first powder layeris provided is either a powder bed or a start plate.
 8. The apparatusaccording to claim 1, wherein said energy beam is an electron beam. 9.The apparatus according to claim 8, wherein said means for directingsaid energy beam over said first powder layer is a magnetic coil. 10.The apparatus according to claim 1, wherein said powder is metallicpowder.
 11. The apparatus according to claim 1, wherein saidpredetermined amount of powder is provided on a powder table.
 12. Theapparatus according to claim 11, wherein said powder table is a powdercontainer with a movable floor for providing said predetermined amountof powder.
 13. The apparatus according to claim 1, wherein said meansfor providing said predetermined amount of powder is a rotating barrel.14. The apparatus according to claim 1, wherein said means for providingsaid predetermined amount of powder is a powder hopper.
 15. Theapparatus according to claim 14, wherein said powder hopper has anopening at a bottom portion of the powder hopper.
 16. The apparatusaccording to claim 15, wherein a mechanical shutter is positionedadjacent the opening and configured to selectively open and close theopening for providing said predetermined amount of powder.
 17. Theapparatus according to claim 1, wherein said energy beam is a laserbeam.
 18. The apparatus according to claim 17, wherein said means fordirecting said energy beam over said first powder layer is a reflectingmirror.
 19. The apparatus according to claim 18, wherein said reflectingmirror is tiltable.